Method of and apparatus for manufacturing subdivided soap product



Oct. 28, 1947. P; w. TAINSH 2,429,852

METHOD OF AND APPARATUS FOR MANUFACTURING SUBDIVIDED SOAP PRODUCT Filed Feb. 2, 1945 Pe+eh Wrigh+ Tuinsh INVENTOR BY Wink W & (ll WW n HIS ATTQRNEYS Patented Oct. 28, 1947 IVIETHOD OF AND APPARATUS FOR MANU- FACTURING SUBDIVIDED SOAP PRODUCT Peter Wright Tainsh, Spital, England, assignor to Lever Brothers Company, Cambridge, Mass., a corporation of Maine Application February 2, 1943,-Serial No. 474,432 In Great Britain February 4, 1942 "12 Claims. '1

The present invention relates to a soap product in novel subdivided form, and more particularly, to soap in the form of small pieces having improved structural and other characteristics adapting the same to be used advantageously 'for dishwashing, laundering, and other general household purposes. The invention also includes a method of manufacturing the improved subdivided soap product.

In accordance with the prior art, subdivided soap is frequently prepared in the form of flakes. Soap flakes are produced conventionally, for example, by forming a sheet of solidified soap by the use of rolls and thereafter removing the soap from the rolls in the form of flakes of predetermined shape, for example, in the form of small flat rectangles. If desired, the sheet of soap on the rolls may be formed by flowing a molten soap, for example, a kettle soap, onto chilling rolls. In order to prepare a better-grade of soap flakes, however, it is conventional to reduce the moisture content of the soap and thereafter subject the same to a milling operation. In the milling operation, the thin sheet of soap as it leave the mill is cut or scored in the form of flakes.

The cutting or scoring of the soap generally is accomplished by utilizing an auxiliary roller which is equipped with a-cutting device for dividing or scoring the thin sheet of soap. Generally, the cutting'device is so arranged that the sheet is only partially out through so that the soap still adheres along the lines out or scored by the cutting device. The soap maybe removed from the rollby applying thereto a scraper blade extending across thewidth of the roll. The-scraper blade separates the soap from the roll and at the same time the'shee't of soap breaks alon the scored orcut lines in the form of flakes. The soap which does not break into flakes along the scoring, generally becomes separated during the subsequent handling and packing operations.

It is a disadvantage of soap flakes, prepared in accordance with the prior art, that they are susceptible to coalescence or felting, etc., which causes them to adhere together. This'is particularly noticeable When'the soap flakes are maintained in a warm, moist atmosphere. The sticking together of the soap flakes to form large agglomerates-defeats the primary object of forming the soap into small subdivided form. This is also disadvantageous "when the soap flakes are putin Water, for they tend to form a mat or solid mass on top of the Water, which greatly retards the penetration of the water into the soap, thus reducing the rate ofdissolutionof the soap.

A further disadvantage of the soap flakes of the prior art is that they have a heavy bulk density. In general, the flakes have a tendency to pack tightly together to form a mass having few voids and little entrapped air. As a, result, the bulk density of the soap tends to approach that of solid soap. Some attempts have been made heretofore to decrease the bulk of the soap by including diluents and soap builders, but this generally is unsatisfactory because it affects the purity of the-soap. Because of the heavy bulk density of conventional soap flakes, they are often used wastefully, for example, because they are used in excessive amounts.

A further disadvantage of soap flakes prepared in accordance with the .prior art is that it is difficult to form flakes having .a desired solubility. For example, it-has been observed that difiiculty is experienced in bringing about, the desired rapid dissolution of conventional soap flakes in water heated to the degree generally preferred in ordinary household usage. Although the solubility of the soap may depend-in part, upon its physical form as discussed above, other factors, such as the soap formula, also are involved. However, it is not advantageous to increase the solubility of the soap, for example by modification of the soap formula, beyond apoint at which the'other characteristics of the soap are deleteriously affected. The art long has sought-a method of further increasing'the solubility of soap in subdivided form Without, at the same time, materially detracting from the usefulness of the product.

It is an advantage'ofthe soap product prepared in accordance with the present invention that the foregoing-difiiculties observed in connection with conventional soap flakes have been overcome. In accordance with the present invention, the soap in subdivided form is rendered more soluble and of less bulk density, While the tendency of the soap flakes to adhere together is materially reduced. In addition to the foregoing advantages, the'soap product of the present invention has a distinctive and novel form, rendering it 'more' attractive and advantageous-to the user.

In' accordance with the present invention, the soap :in subdivided-form is-m'odifiedphysically'to produce a product having-a crimpcd, corrugated or similar form. The-invention also includes the preliminary step, if desired; ofmodifying the soap base so-that the soap'may'be in a plastic or deformable condition when subjected to the desired crimping -or similar-deformation. In addition, this latter --m'odiflcation may have the advantage of improving the solubility of thesoapjproduct.

In carrying out the invention, any soap or detergent base, with or without diluents, which is suitable to be formed into subdivided soap products, such as conventional flakes, may be used. The preparation of such a soap base is well within the knowledge of one skilled in the art and does not form a part of the present invention except in so far as the soap is rendered more plastic, as discussed more fully hereinafter.

In accordance with the present invention, the soap base is first made into a scored or perforated sheet, for example, in the same Way as this is done in the conventional methods of making soap flakes, as discussed above. The method utilized for forming the perforated or scored sheet is not critical and may be varied as desired. For convenience of illustration and to aid in the understanding of the invention, the invention will be described more particularly in connection with the method of making a scored or perforated soap sheet. described above. It will be apparent from the present disclosure, however, that this has been done merely for convenience, and that perforated or scored soap sheets prepared in other ways may be similarly treated. The invention is illustrated in the sheet of drawings attached hereto showing a View of an apparatus which may be utilized and the resulting product.

Figure 1 shows the arrangement of a crimping device on a -roll mill of the type usually employed for the manufacture of soap flakes, and

Figure 2 illustrates one form of crimped flake.

The mill comprises a feed hopper I, four intermediate rolls 2, a topmost roll 3, two cutting rolls 4 resting on the topmost roll 3, scraper knife 5 held in position by a scraper knife holder 6, to which is fixed a crimping bar 1 with crimping face 8 and a parallel-sided delivery chute 9 of suitable inclination. The crimping bar 1 extends across the width of the mill and is desirably adjustable to any suitable distance from the topmost roll 3, and its dimensions may be varied.

In the operation of the mill, the soap passes from the feed hopper l between the intermediate rolls 2 to the topmost roll 3, where the thin film of soap iscut by the cutting rolls 4 into long narrow rectangles or near rectangles. The scraper knife 5 strips the film off the topmost roll 3 and the advancing plastic cut film of flakes (which flakes have not yet completely separated from one another along the lines of the cuts) presses forward and crumples up against the crimping face 8 with the result that the flakes pass over the face in the form of numerous little concertinas, which may still be partly joined to one another along their edges, although they quickly become completely separated from one another during subsequent handling and packing operations.

The crimped I flakes after passing over the crimping face 8 slide gently down the parallelsided chute 9.

In this embodiment of the invention, the scored or perforated soap sheet separated from a roll in a conventional way is subjected to physical deformation to give it a crimped, corrugated or similar shape as distinct from its original flat form. It may be possible to carry out the crimping or deforming of the soap in a wide variety of ways Within the scope of the present invention. For convenience, I prefer to carry out the deformation mechanically. In accordance with the invention, I have discovered, for example, that the deformation of the soap sheet coming from the rolls may be carried out mechanically in a convenient and efficient manner by providing an obstruction on the scraper blade holder, whereby the soap sheet removed from the roll by the scraper blade is caused to press against the obstruction and thus crumple up into a desired accordion like, crimped, corrugated or similarly deformed shape.

As a specific example of an apparatus of the kind referred to, the scraper blade holder may be formed with a metal strip preferably extending across the entire width of the blade near the cutting edge thereof. As will be apparent from the disclosure, the dimensions of the metal strip may be varied over a wide range. As a specific example, a strip in the neighborhood of about% inch in thickness and 2 inches wide has been utilized successfully. For convenience, the metal strip may be made adjustable so that the distance from the rollers may be regulated. I have found that it may be desirable, for example, to adjust the position of the metal strip so that the upper face or edge of the strip is in the neighborhood of about inch from the edge of the scraper blade. This may vary widely depending upon the size of the soap flakes, the extent of deformation desired, and other factors.

The function of the strip or other obstruction aflixed to the scraper blade is to prevent the free passage of the sheet of soap removed from the roll across the scraper blade whereby a desired physical deformation of the soap sheet will take place. As a specific example of the operation of the device, it will be assumed for convenience that the sheet of soap on the roll is cut or scored into long narrow rectangles or near rectangles, for example, of the size of about 1 /2 by inches. These rectangles preferably are formed on the roll and are removed by the scraper blade so that they feed endwise (with the smallest dimension) against the face or edge of the metal strip positioned on the scraper blade holder. The advancing plastic sheet which has not yet separated along the lines of the scoring, presses forward against the face wedge of the metal strip and P crumples up until the cut portions separate from one another and pass over the top of the metal strip in the form of numerous concertinas. Some of the concertinas may still be joined to one another along their edges, although they quickly become completely separated from one another during subsequent handling and packing operations.

The degree of crimping of the soap pieces, that is to say, the number of accordion folds and their closeness together, may be varied by altering the distance of the strip from the edge of the scraper blade. The folds, however, should not be so close together as to prevent water passing between them and thereby reduce the rate of solution of the flakes.

After the soap is crimped or corrugated by the action of the strip or other obstruction or the scraper blade, it is preferred, in accordance with the present invention, to permit the soap pieces to slide to the collecting bins or other apparatus along a chute or similar surface having only a slight inclination. It has been found that the slope of the chute or other surfaces preferably should be moderate, inasmuch as with steep inclinations, there is an increasing tendency for the concertinas, while passing down the chute in a plastic condition, partially to straighten or expand themselves. For convenience the slope of the chute or surface may be made, for example, of the order of about 30 degrees to the horizontal.

It may be preferred in accordance with the present invention to utilize an adjustable chute or other surface so that the slope may be reguulated as required. By regulating the inclination of the chute or other surface, the degree of corrugating or crimping of the final product may be adjusted as desired.

I have observed that conventional soap bases, particularly those of reduced moisture content, may be too brittle or otherwise unworkable for mechanical modification in accordance with the invention. This disadvantage, if it exists, may be overcome in accordance with the present invention, by modifying the soap base by adding thereto a plasticizing agent. As :a result of such additions, it is possible to render the soap sufficiently plastic .so that it may be mechanically deformed, in accordance with the invention, without breaking up to any serious extent.

For convenience, the plasticizer may be added to the soap during. the finishing operations and prior to solidification. If desired, however, it may be preferred to add the plasticizer to the soap during the milling operation, if this operation is utilized. This latter procedure is preferable inasmuch as it has a more pronounced effect upon the solubility of the soap flakes as discussed. hereinafter.

In general, any plasticizer is suitablefor' this purpose. As specific examples, there may be mentioned the partial esters of fatty acids with glycerol and polyglycerols, such as the mixed monoand d-iesters of coconut oil fatty acids with slightly polymerized glycerol. Other Well-known plasticizing agents which may be mentioned by way of illustration are mineral oil, fatty acid partial esters of glycol, or polyglycols. Other specific examples are sorbitol and soluble condensation products of unsaturated alcohols. If desired, there may be used the water. soluble waxes, such as the product known under the trade name Carbowax which is a polymerized glycol. The foregoing specific examples have been given merely by way of illustration and to assist in the understanding of the invention, and it is not intended that the invention shall be limited thereto. The materials included within the scope of the term plasticizers, which may be added to the soap, are well known to one skilled in the art, and the use of all such materials is intended to be Within the scope of the invention.

Inasmuch as the physical properties of the soap to be treated in accordance with the invenion may vary widely as a result of the formula or temperature conditions, etc., it will be found that the amount of plasticizer added may vary over a, Wide range. In general, it is not desired to utilize substantially more than about 20% plasticizer, inasmuch as with the use of greater amounts, the soap flakes may suffer an undesirable reduction in lathering power. On the other hand, very small amounts, such as 1% or less, of plasticizer may have too small a plasticizing effect to obtain the desired results. In specific operations I have preferred to use about of plasticizer and preferably in the range of 5-l5%. By varying the amount of plasticizer present, the plasticity of the soap may be controlled so that, other factors remaining constant, the desired corrugating or crimping of the soap flakes will result.

It is an advantage of the present invention that the use of the foregoing plasticizers, in addition to their value for rendering the soap more deformable, also have the property of increasing quickly soluble.

6 the solubility of the soap pieces. This improvement is particularly marked at the temperatures frequently utilized for dishwashing and other householdoperations and may result even though the amount of plasticizer present is as little as 5% or less.

The distinctive and unique form of the soap productprepared in accordance with the present invention, besides rendering the product more attractive to the user, I have found, materially decreases the tendency of the soap pieces to adhere together', and at the same time, the bulk density of. the soap is desirably reduced. The penetration of the water into the soap during use is facilitated whereby the soap is rendered more This latter effect is enhanced by the presence of the plasticizers, if they are used, which also have a beneficial effect upon 'the solubility of the soap.

In view of the present disclosure, many modifications and variations of the invention will be suggested to one skilled in the art, and all such modifications and variations are intended to be included within the scope of the invention,

1 claim:

I. A method of preparing a subdivided soap product of relatively low bulk density and increased solubility which comprises forming a soap base, adding about 5-15% of a plasticizer to said soap base, formin the soap base into a scored sheet, exerting a bending force on said sheet of soap to impart a crimped form thereto, and maintaining said crimped form until the soap is substantially form-retaining.

2. .A. method of preparing a subdivided soap product of relatively low bulk density which comprises forming a soap base, adding about 1-20% of a plasticizer to said soap base, forming the soap base into a sheet of soap, scoring the sheet of snap to form small sections, and mechanically crimping thesoa'p sections and maintaining them crimped until substantially form-retaining,

3. A method of preparing a novel subdivided soap product which comprises forming a soap base, adding a plasticizer to said soap base, forming the soap base into a scored sheet, and imparting a crimp to the scored sheet and separating it along the scoring.

4. A method of preparing a novel subdivided soap product which comprises forming a scored sheet of soap on a supporting surface, removing the scored sheet of soap from the supporting surface and moving said removed scored sheet of soap laterally in abutment against the face of a thin strip disposed substantially at right angles to the movement of the sheet of soap to crumple the scored sheet into accordion pleated pieces.

5. A method of preparing a novel subdivided soap product which comprises adding a plasticizer to a soap base, forming the soap base into a scored sheet of soap on a supporting surface, removing the scored sheet of soap from the supporting surface and moving said removed scored sheet of soap against an obstruction whereby the sheet of soap is deformed into crumpled pieces.

6. A continuous method of preparing a novel subdivided soap product which comprises continuously forming a scored sheet of soap on a supporting surface, and continuously moving said sheet of soap, after removal from the surface on which the sheet was formed, in abutment against the face of a thin strip to form accordion pleated pieces of soap.

7. A method of preparing a novel subdivided soap product which comprises forming a soap base, adding not more than about 20% of a plasticizer to said soap base, forming the soap base into scored sheet form on a supporting surface, removing said scored sheet from the supporting surface and moving said scored sheet of soap after removal from said supporting surface against a thin barrier whereby the pieces of soap formed by said scoring are subjected to a bending stress.

8. A method of forming a novel subdivided soap product which comprises scoring a sheet of soap to form small rectangles while supported on a roll, removing the scored sheet of soap from the roll and after the removal thereof passing the rectangles edgewise in abutment against the face of a thin strip to form accordion pleated pieces of soap.

9. A method of forming a novel subdivided soap product which comprises adding a plasticizer to a soap base, forming the soap base into a thin sheet which is dividedby partial cutting into small rectangles while supported on a roll, removing the partially cut sheet of soap from the roll and after the removal thereof passing the rectangles edgewise against a thin barrier to impart a crimp thereto.

10. An apparatus for forming anovel subdivided soap product which comprises a rotatable roll, means for forming a scored sheet of soap on said roll, a blade for removing the scored sheet of soap from the roll as the roll is rotated, a thin strip adjacent and substantially parallel to the edge of the blade to accordion pleat said scored sheet of soap, and a surface inclined at an angle not substantially greater than 30 to the horizontal along which the soap passing across the said thin strip may slide.

11. In an apparatus for forming thin pieces of soap having a crimped form comprising a roll and a scraper blade mounted against the roll, a

strip adjacent and substantially parallel to the scraping edge of the blade, said strip being about two inche wide and one-eighth inch thick and extending substantially throughout the length of the blade, said strip being mounted about 16 of an inch from the scraping edge of the blade.

12. An apparatus for preparing a subdivided soap product, which comprises means for continuously forming the soap base into a scored sheet, means for continuously moving said scored sheet lengthwise of its path and along a cylindrical path, a scraper blade for continuously removing said moving sheet from said cylindrical path, and a thin strip in close proximity to the scraper blade, the face of said strip being parallel to the scraper blade for continuously deflecting said removed sheet to crimp and accordion pleat the same transversely of its length.

PETER WRIGHT TAINSH.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS Number Name Date 576,159 Rutschmann Feb. 2, 1897 790,021 Arkell May 16, 1905 850,003 Houchin Apr. 9, 1907 1,436,939 Zink Nov. 28, 1922 1,481,417 Cove Jan. 22, 1924 1,633,689 Thal June 28, 1927 1,942,418 Forte 1 Jan. 9, 1934 2,142,983 Thurman Jan. 3, 1939 2,249,676 Thurman July 15, 1941 2,251,328 Ehret Aug. 5, 1941 FOREIGN PATENTS Number Country Date 373,408 Great Britain May 26, 1932 Certificate of Correction Patent No. 2,429,852. October 28, 1947.

' PETER WRIGHT TAINSH It is hereby certified that error appears in the printed specification of the above numbered patent requiring correction as follows: Column 8, list of references cited, under the heading UNITED STATES PATENTS for the number 1,436,939 read 1,436,929; and that the said Letters Patent should be read with this correction therein that the same may conform to the record of the casein the Patent Office.

Signed and sealed this 24th day of February, A. D. 1948.

THOMAS F. MURPHY,

Assistant Commissioner of Patents. 

